Opel Astra, Zafira

since 1998 of release

Repair and car operation

Opel Astra
+ Opel Astra and Zafira Cars
+ Operation manual
+ Routine maintenance
+ Engine
+ Systems of cooling, heating
+ Power supply system and release
+ engine Electric equipment
+ Manual transmission
+ Automatic transmission
- Coupling and power shafts
   - Coupling
      Coupling - the general information and check of a condition of components
      Removal and installation of the main cylinder of coupling
      Removal and installation of assembly of the executive cylinder of coupling with the vyzhimny bearing
      Air removal from a hydraulic path of a drive of switching off of coupling
      Removal and installation of a pedal of coupling
      Removal, check of a condition and installation of components of coupling
   + Power shafts
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment

Removal, check of a condition and installation of components of coupling

Remember that developed in the course of wear of frictional overlays of a conducted disk of coupling the dust can contain unhealthy asbestos. Do not blow off a dust the compressed air and try not to inhale it. Do not apply to rubbing of components of coupling solvents on an oil basis — use only special brake cleaners or pure methyl alcohol. The used rags put in tightly closed container.


For the purpose of ensuring access to coupling assembly usually remove a transmission, leaving the engine on the car. If the engine is already removed for performance of the general or major maintenance, the condition of components of coupling should be checked without fail. Considering rather low cost of details and rather large volume of metalwork works on ensuring access to coupling assembly, it is meaningful to make replacement the with the last regardless of a condition of its components. The description of procedure of removal of coupling without engine extraction from the car below is provided.


  1. Remove a gear shifting box (see. Head the Manual transmission) — prop up the engine a jack, or hang out it from above on the winch (preferably the last). In case of use of a jack do not forget to lay between its head and the case pallet wooden whetstone for the purpose of loading distribution.

Maslozabornik of the oil pump settles down very close to the bottom of the pallet of a case and can be easily damaged at deformation of the last.

  1. In order to avoid loss of a conducted disk at basket removal, pass in its nave the tool intended for centering of coupling.
  1. Attentively examine surfaces of a flywheel and assembly of a basket of coupling on marking existence (usually in the form of the letters put with white paint X or About). If to find marking it is not possible, put it independently, having unequivocally marked the provision of a basket concerning a flywheel.
  1. Operating in a diagonal order, in stages (on a half of turn for an approach) evenly weaken bolts of fastening of a basket of coupling to a flywheel, having completely unloaded a diafragmenny spring — before an otpuskaniye of bolts the flywheel can be blocked by means of the special adaptation.
  1. Reliably supporting coupling assembly, finally turn out bolts, then separate a basket from a flywheel and remove all assembly from the car.
  2. Remove a frictional disk — try to remember, it is established by what party on a flywheel.


Assembly of a conducted disk

1 — Frictional slips in a picture are worn-out below an admissible limit
2 — Torsionnye springs or dampers should be checked on existence of cracks and deformation signs

3 — the nave Equipped with shlitsa should slide freely on shlitsa of primary shaft of a transmission, shlitsa should not be excessively worn-out
4 — Rivets are used for fastening of frictional slips and at excessive wear of the last start to leave a furrow on a working surface of a flywheel

Examples of wear of a diafragmenny spring

More often violation of serviceability of functioning of coupling appears connected with wear of frictional overlays of a conducted disk. Nevertheless, it is necessary to study attentively a condition of all other components of assembly.


  1. Study a working surface of a flywheel on existence of cracks, traces of an overheat, furrows and other damages. Insignificant defects can be eliminated with a pro-point way in the conditions of a car-care center workshop (the pro-point is recommended to be made regardless of a surface condition). The description of procedures of removal and installation of a flywheel is provided in appropriate section of Head the Engine.
  1. Also check a condition and estimate planeness of an interfaced surface of a press disk of coupling.
  2. Estimate degree of wear of frictional overlays of a conducted disk of coupling. The surface of slips should tower over heads of rivets at least on 1.6 mm. Make sure of density of landing of all rivets, check torsionny springs / dampers on existence of cracks, traces of deformation and other mechanical damages (see an illustration Assembly of a conducted disk). Zamaslivaniye of frictional slips is the result of failure of an epiploon of a cranked shaft, violation of integrity of laying of the pallet of a case, a sealing element of assembly of the executive cylinder or an epiploon of primary shaft of RKPP more often — replace the damaged components (see the corresponding Chapters). As it was already mentioned above, replacement of components of coupling it is reasonable to make each time at assembly dismantle therefore pay attention to the slightest errors.
  3. Together with a conducted disk as well vyzhimny the bearing always is replaced. If a conducted disk as it should be, check a condition of the vyzhimny bearing, - the bearing should rotate smoothly, without jamming signs. Interfaced surfaces should be absolutely smooth and not damaged, without cracks, задиров and hollows. In the absence of confidence of definition of a condition of the bearing make replacement of assembly of the executive cylinder (see. Removal and installation of assembly of the executive cylinder of coupling with the vyzhimny bearing).
  1. Estimate a condition of the processed surfaces and petals of a diafragmenny spring of a press disk (see an illustration Examples of wear of a diafragmenny spring). In case of detection of defects replace basket assembly. Traces of easy polishing can be removed by means of a fine-grained emery paper. Through firm car repair shops of the Opel company always it is possible to get the restored assembly of coupling on an exchange basis.



  1. Make sure of absoluteness of purity and dryness of interfaced surfaces of a flywheel and coupling disks, in case of need wipe working surfaces solvent.
  2. Establish frictional acting part of a nave from a flywheel. Usually the factory marking indicating is put on a disk, what party to a flywheel it is necessary to establish it («Flywheel side» or «Getriebeseite»).
  3. Establish a coupling basket, - if the old basket is established, track correctness of combination of the landing labels put in the course of dismantle. Screw bolts of fastening of a basket and tighten them while only by hand for the purpose of a possibility of a free centering of a conducted disk.
  4. Now it is necessary to center a frictional disk that at transmission installation its primary shaft passed through a shlitsa in a disk and got to directing plug in a pin of a cranked shaft.
  1. To center a frictional disk it is possible by means of a screw-driver passed through its central opening and entered into directing plug of a cranked shaft. Essentially facilitates a task application of a special opravka (such as the adaptation No. 2174) in the form of a pin of primary shaft of transmission. Quite good results are reached also by means of a thin core with reeled up on it till the demanded diameter an insulating tape.

  1. Having finished a centering of a conducted disk, in stages in a diagonal order evenly tighten bolts of fastening of a basket with demanded effort. Take aligning adaptation.
  2. Establish into place a transmission (see. Head Manual transmission).